DE202018000735U1 - Apparatus configured to carry out a method of designing a component - Google Patents

Abstract

Device (100) configured to carry out a method for designing a component (1) which is produced by means of a beam melting process as a generative production method, in particular by means of selective laser melting, in a system (200) for the generative production of the component (1) Steps: - computer-aided design of the component (1) in a first component design, - computer-aided simulation of the production of the component (1) in the system (200), wherein the component (1), with respect to a component platform (9) in the system ( 200), in a first setup angle (W1) is aligned, - computer-aided determination of a first component area-dependent surface roughness (RA1), - computer-aided determination of at least a first supporting cross-section (Q1) of the component (1) in the region of the determined first surface roughness (RA1) ,

Description

The utility model relates to a device configured to carry out a method for designing a component which is produced by means of a jet melting method as a generative manufacturing method, according to the preamble of claim 1.

Components which are produced by means of jet melting as a generative production method, in particular by means of selective laser melting (SLM), generally have a surface roughness which is further processed by finishing to a final dimension. Especially in edge zones of the component, based on a positioning of the component on a construction platform in a system for generative production, particularly high surface roughness occur. At these edge zones, the laser beams for curing a powder material in an SLM process often strike the component surface at an acute angle compared to a more obtuse angle in the central area of the component surface. On the other hand, the angle of incidence of the laser beam depends substantially on the positioning of the component on the construction platform in the system for generative production, that is to say, for example, on an assembly angle of the component on the construction platform. If this setup angle is changed, the angle of incidence of the laser beam on the component surface also changes as a rule. In particular, this can lead to blunt angles of incidence, which in turn can lead to lower surface roughness.

The surface roughness, especially with thinner component structures, significantly influences the load-bearing cross section in the component area of this surface roughness. Therefore, the influence of the surface roughness on the load-bearing cross-section should already be taken into account in the construction of the component or in a construction project (virtual creation of the layer model of the component as a basis for generative manufacturing in the plant). This applies in particular to areas of the component that are not accessible from the outside.

According to the state of the art, the cross-section is usually expanded or thickened on the basis of empirical values, for example, with the aid of CAD (computer-aided design) software for computer-aided design, in areas with a high surface roughness. This is often due to the fact that the components produced by means of an SLM process are blasted for surface finishing and thereby the clear points are removed so that the component has a required final dimension after blasting. Inaccessible areas of the component, ie in particular internal areas and structures that are not accessible from the outside, can not be sufficiently considered for this blasting. Therefore, a thickening of these inaccessible areas, depending on the surface roughness, usually does not take place. The surface roughness can, as has already been described above, depend essentially on the build-up angle of the component on the build platform in the system for generative production. In addition, only an accessible final contour, ie surface areas that can be processed, in particular from the outside, are taken into account for a thickening or for a correction of carrying cross sections, but not carrying cross sections of inaccessible, in particular internal structures.

One object is to propose a device that is configured to carry out a method for designing a component which is produced by means of a beam melting method as a generative production method in a system for the additive production of the component.

The object is achieved by a device having the features of claim 1.

A device is claimed which is configured to carry out a method for designing a component which is produced by means of a beam melting method as a generative production method, in particular by means of selective laser melting, in a system for the additive production of the component. The method comprises as a first step a computer-aided design of the component in a first component design. The second step of the method comprises a computer-aided simulation of the production of the component in the installation, wherein the component is oriented in a first installation angle relative to a component platform in the installation. The third step of the method comprises a computer-aided determination of a first, component-area-dependent surface roughness. The fourth step of the method comprises a computer-aided determination of at least one first supporting cross section of the component in the region of the determined surface roughness.

Advantageous developments are the subject of subclaims and embodiments.

Exemplary embodiments may have one or more of the following features in any combination, provided one or the concrete combination is not apparent to the person skilled in the art as obviously technically impossible. The subject matters of the subclaims in each case give exemplary embodiments.

In all of the above and below, the use of the term "may be" or "may have" etc. is synonymous with "preferably" or "preferably", etc., and is intended to exemplify exemplary embodiments.

Whenever alternatives are included herein with "and / or", those skilled in the art will understand the "or" contained therein as preferably "either or" and preferably not as "and".

Embodiments referred to herein are to be understood as purely exemplary embodiments, which are not to be construed as limiting.

The device may be a computer in some embodiments. The configuration of a computer configured as a device may be a program, a computer program or the like for carrying out the method.

A generative manufacturing process can be referred to as additive manufacturing (abbreviated: additive manufacturing, abbreviated AM) or as a process for additive manufacturing. A generative manufacturing process can be carried out on the basis of computer-generated data models. In a generative manufacturing process, a component can be produced from informal (liquids, gels / pastes, powders or the like) and / or from form-neutral (eg strip-shaped, wire-shaped, sheet-shaped) materials or materials by means of chemical and / or physical processes.

A computer-aided design of the component in a component design may refer to component design with respect to design parameters and / or component design with respect to manufacturing-related parameters. In a production of the component by means of a generative manufacturing process, dimensions, surface roughness and / or structural properties of the component may change as the production-related parameters change.

A component area dependent surface roughness may be a surface roughness of a single component surface. A component surface may be an inner or an outer component surface. A component surface can refer to individual areas, segments, sections.

In some embodiments, the apparatus configured to carry out a method of designing a component that is manufactured by a beam fusion process as a generative manufacturing process in a device for the additive manufacturing of the component comprises the further following steps. The steps include a computer-aided design of the component in a second component design, a computer-aided simulation of the production of the component in the system, wherein the component, with respect to a component platform in the system, is aligned in a second setup angle, a computer-aided determination of a second, component-dependent area Surface roughness, as well as a computer-aided determination of at least one second supporting cross-section of the component in the region of the determined surface roughness. The first and second mounting angles are different. By way of example only, the first assembly angle may be 60 degrees, 75 degrees, 90 degrees, 120 degrees, or another value, the second assembly angle may be 0 degrees, 30 degrees, 45 degrees, or another value.

In some embodiments, the apparatus configured to carry out a method of designing a component that is manufactured by a beam fusion process as a generative manufacturing process in a device for the additive manufacturing of the component comprises the further following steps. The steps include evaluating (the term evaluating may mean or comprising analyzing) at least one of the preceding method steps regarding the relationships between the surface roughness, the load-bearing cross-section and the orientation of the component in the system, a determination of the orientation of the component in the system based on the evaluation of the preceding method step, in particular with a dimensioning of at least one load-bearing cross-section, and a production of the component in the system, based on the construction of the preceding method step. An evaluation of a relationship between the surface roughness, the supporting cross-section and the orientation of the component in the system can, purely by way of example, be that a first component design is compared with a second component design. Both component designs can be defined or defined by means of the parameter of the alignment of the component in the system, all other parameters (constructional or geometrical parameters, material characteristics etc.) are optionally not changed. The first component design is, purely by way of example, with an orientation of the component, based on a mounting angle of z. B. 90 degrees. This yields, based on a computer-aided simulation of the generative production in the plant, a mean surface roughness in a certain area of the component surface of z. B. approximately R _a = 40 microns and a load-bearing cross-section of z. B. 10 mm. These values are determined in particular by means of the simulation software and, if necessary, with another software. In a subsequent second component design, purely by way of example, the orientation of the component, based on a mounting angle of z. B. 60 degrees. This can, based on a computer-aided simulation of the generative production in the system, a mean surface roughness in a certain range of the component surface of z. B. approximately R _a = 25 microns and a load-bearing cross-section of z. B. 15 mm. A comparison of the two component designs in an evaluation of the relationship between the surface roughness, the load-bearing cross-section and the orientation of the component in the system results in a larger load-bearing cross-section for the second component design. As part of the process step of determining the orientation of the component in the system, therefore, this second design can be selected, which is based on a mounting angle of 60 degrees. As part of the subsequent process step, this construction angle of 60 degrees is selected for the real production of the component in the plant for generative manufacturing of the component.

In some embodiments, the apparatus configured to perform a method of designing a component manufactured by a jet-melting process as an additive manufacturing process in a device for additive manufacturing of the component comprises at least the further step of using at least one material simulation for computer-aided design of the component a component design. A material simulation can include, for example, a computer-aided modeling of a material microstructure and / or mechanical material properties. The step of using a material simulation may be performed in addition to a selected setup angle.

In some embodiments, the apparatus configured to carry out a method of designing a component that is manufactured by a beam melting process as a generative manufacturing process in a device for additive manufacturing of the component, comprises the further step of using at least one influencing factor to account for the material properties. The material properties may include, for example, mechanical and / or physical material properties.

Some or all embodiments may have one, several or all of the advantages mentioned above and / or below.

By means of the device can advantageously be provided to the designers of components an aid in the component design available. In particular, design errors due to insufficient wall thicknesses can be avoided or prevented. By means of the device, the effective load-bearing cross-section can be determined by means of the computer-aided simulation.

By means of the device can advantageously be carried out using the computer-aided simulation, an analytical and / or reproducible design process. A complex, iterative design process with changes in constructive data, which includes a first design with a subsequent check on the basis of a created component, then a second construction with a further subsequent review based on a created component and optionally further steps eliminates advantageous. Furthermore, eliminating a costly, iterative design process can advantageously result in cost savings and / or time savings.

By means of the device can also be advantageously carried out an efficient use of the material potential. In particular, based on the computer-aided simulation of the manufacturing process, this use of the material potential can be performed more efficiently compared to a step-by-step implementation and analysis of real manufacturing processes, which can be time-consuming and / or expensive.

The utility model is explained below by way of example with reference to the accompanying drawings, in which identical reference numerals designate identical or similar components. In each case greatly simplified schematic figures:

1 shows an exemplary apparatus that simplifies the method step of a computer-aided design of an exemplary component;

2 shows the exemplary device that performs the method step of a computer-aided simulation of the production of the component at a first assembly angle in a system;

3 FIG. 12 shows the exemplary apparatus performing the method steps of a computer-aided determination of a surface roughness and a load-bearing cross-section based on the first setup angle; FIG.

4 shows the exemplary device that performs the method step of a computer-aided simulation of the production of the component in a second assembly angle in a system;

5 shows the exemplary apparatus performing the method steps of a computer-aided determination of a surface roughness and a load-bearing cross-section based on the second setup angle; and

6 shows the exemplary device, which is the method step of a production of the component, which is aligned in the second construction direction in the system executes.

1 shows a device 100 describing the method step of a computer-aided construction of an exemplary component 1 performs. The purely exemplary component 1 is angled, which has an internal channel 3 with a grid-shaped insert 5 having. The grid-shaped insert 5 will with striving 7 in the channel 3 fixed or anchored. This purely exemplary component 1 is merely illustrative of the device 100 for carrying out a method of designing the component 1 is configured. The component 1 could for example be used in a machine, in a plant, in a building or elsewhere.

The computer-aided design is preferably by means of a computer 100 as a device 100 executed. The computer-aided design may be performed by a user operating a computer-aided design (CAD) program installed on the computer.

The construction of the component 1 is in particular under the specification of a later production by means of a beam melting process as a generative manufacturing process, in particular by means of a selective laser melting process designed. This manufacturing method allows special constructive freedom, for example, the construction of internal structures or undercuts, which are at least difficult to implement with conventional manufacturing processes, such as material removal processes or primary molding.

The component 1 is preferably made of metal. The generative production method of selective laser melting is particularly suitable for this purpose.

2 shows the computer 100 , which is the method step of a computer-aided simulation of the production of the component 1 , in a first mounting angle W1 in a plant 200 (please refer 6 ). This simulation leads with a suitable software the entire manufacturing process for generative manufacturing of the component 1 in a virtual environment. By means of this simulation, for example, different process parameters can be set and their effect on the manufactured product can be tested and analyzed. Such process parameters can be, for example, material characteristics, laser parameters or the orientation of the component 1 , related to a component platform 9 in the plant 200 , be.

In 2 is the orientation of the component 1 , related to the component platform 9 , determined by a first mounting angle W1. As a reference example, the right end face of the component is selected, another reference is also possible. The first mounting angle W1 has a value of approximately 90 degrees. The component 1 is layered in this virtual environment from below, starting from the component platform 9 , built up layer-by-layer in the y-direction. The laser 11 solidified by means of a laser beam 13 the component 1 in layers per layer plane 15 before the component platform 9 is gradually lowered (see 6 ).

How out 2 can be seen, the laser beam hits 13 , depending on the set or selected mounting angle W, at different angles to the component surface to be solidified. The component surface may be an inner or an outer component surface. The component surface can be on a wall 17 , the grid-shaped insert 5 or the struts 9 Respectively. At the in 2 chosen first mounting angle W1 of about 90 degrees hits the laser beam 13 for example, in the area of the left (referring to the illustration in 2 ), outer component surface at a particularly acute angle to the component surface. This can have an effect on the roughness of the surface as it is in the 3 . 4 and 5 further executed and described.

3 shows the computer 100 which executes the method steps of computer-aided determination of a first surface roughness RA1 and a first supporting cross section Q1 based on the first setup angle W1. The basis for this method step is the computer-aided model of the previously designed component. The enlarged section A shows, greatly simplified shown, a surface roughness RA1, as by the solidification of the material by the laser beam 13 can be generated by means of a selective laser melting method (SLM). In general, a certain surface roughness RA is process-dependent by the SLM method and depends, for example, on the particle size of the powder as the starting material for the production process. The height of the surface roughness RA, however, depends in detail on several influencing factors. Of these influencing factors, the superstructure angle W is analyzed in more detail here.

The surface roughness RA in the individual, component-area-dependent segments is determined by means of a suitable simulation software. The transferability of these simulation results to the real manufacturing process has to be checked and validated accordingly. In the embodiment of 3 the surface roughness RA is determined computer-aided on all inner and outer surfaces. By way of example, in section A, the first surface roughness RA1 determined and set in relation to the first setup angle W1. The first surface roughness RA1 becomes conscious in a range with a sharp angle of incidence of the laser beam 13 determined on the surface. Subsequently, in the embodiment of the 4 and 5 the same area of the surface, but determined at a different chosen mounting angle W to determine their influence on the height of the surface roughness RA.

The surface roughness RA, in particular in the case of thin structures, essentially determines the load-bearing cross-section Q. The load-bearing cross-section is a load-bearing surface. From the load-bearing cross-section and attacking forces, the stress in the application can be determined or calculated. The stress load can be called stress. At a high surface roughness RA, caused by a sharp angle of incidence of the laser beam 13 may be caused, the load-bearing cross-section Q may be lower compared to a lower surface roughness RA. Thus, if a lower surface roughness RA, at least in certain, for the component relevant surface areas, can be determined by a suitable choice of a mounting angle W, it is therefore possible to achieve a higher stress or stress in the application. Alternatively, with the same load, for example, the safety factor can be higher or the probability of failure of the component can be rated lower. This can be highly relevant in particular for safety-relevant components, for example in aircraft turbine construction.

In the section A of the component 1 For example, a first load-bearing cross-section Q1 can be determined, which can be determined in a greatly simplified manner as the overall cross-section minus the surface roughness RA1 on the inside and on the outside.

4 shows the computer 100 , which is the step of the computer-aided simulation of the production of the component 1 in a second setup angle W2 in the system 200 performs. The description for 2 applies analogously to 4 ,

The second mounting angle W2 is about 60 degrees. Thus, the component 1 , related to the component platform 9 , tilted by about 30 degrees more to the right or inclined relative to the first mounting angle W1 2 , As a result, the laser beam 13 impinges on the component surface in the considered section A at a substantially less acute angle. This influences the surface roughness RA, as discussed in the discussion 5 is explained in more detail.

Depending on the selected mounting angle W, the component 1 in a later production by corresponding support structures on the component platform 9 stabilized and fixed.

On the basis of the simulation of the production process shown here, different and largely arbitrary mounting angles W can be set as simulation parameters and their influence on the surface roughness RA can be analyzed.

5 shows the computer 100 which executes the method steps of a computer-aided determination of a second surface roughness RA2 and a second supporting cross-section Q2 based on the second setup angle W2. The description for 3 applies analogously to 5 ,

The enlarged section A shows, greatly simplified, a surface roughness RA2, based on the second setup angle W2 and the associated blunt angle of incidence of the laser beam 13 on the surface of the component 1 is smaller than the surface roughness RA1 resulting from the first setup angle W1. This leads to a larger load-bearing cross-section Q2. The discussion about 5 applies analogously to the discussion of 3 , This can mean, for example, that the stress on the component 1 can be higher if the component 1 With the second mounting angle W2 of about 60 degrees, instead of the first mounting angle of about 90 degrees, is manufactured in a SLM process. At least in the simulation this leads to this result.

6 shows the computer 100 , which is the process step of a production of the component 1 , which in the second setup angle W2 in the plant 200 is aligned, executes. On the details of the SLM procedure and the system 200 will not be discussed here, since this is known in the art. The material with which the component 1 is built up in layers, is initially as a powder in a powder well 21 in front. The powder 19 is by means of a lifting table 23 moved upwards (y-direction), leaving a slider 25 (synonymous to coater or recoater) the powder then on the component platform 9 can transport. Subsequently, a thin powder layer by means of the laser beam 13 cured (by means of selective laser melting). Subsequently, the component platform 9 lowered by the hardened layer thickness. This process will take until the complete fabrication of the component 1 continued or repeated.

The finished component 1 can then be checked and measured with regard to the previous simulation.

The finished component 1 can then be surface-treated, for example by means of radiation, and thus achieve a required final size.

LIST OF REFERENCE NUMBERS

100

Contraption; computer

200

investment

Q1

first load-bearing cross-section

Q2

second load-bearing cross-section

RA1

first surface roughness

RA2

second surface roughness

W1

first mounting angle

W2

second mounting angle

x

x-direction

y

y-direction

1

component

3

channel

5

grid-shaped insert

7

holding struts

9

component platform

11

laser

13

laser beam

15

layer plane

17

wall

19

powder

21

coffee chute

23

Lift table

25

slide; coater; recoater

Claims (5)

Contraption ( 100 ) configured to carry out a method of designing a component ( 1 ), which by means of a beam melting process as a generative manufacturing process, in particular by means of selective laser melting, in a plant ( 200 ) for the additive production of the component ( 1 ), comprising the steps of: - computer-aided design of the component ( 1 ) in a first component design, - computer-aided simulation of the production of the component ( 1 ) in the plant ( 200 ), wherein the component ( 1 ), based on a component platform ( 9 ) in the plant ( 200 ), is oriented in a first setup angle (W1), - computer-aided determination of a first, component-area-dependent surface roughness (RA1), - computer-aided determination of at least one first load-bearing cross-section (Q1) of the component ( 1 ) in the area of the determined first surface roughness (RA1). Contraption ( 100 ) according to claim 1, comprising the further steps: - computer-aided construction of the component ( 1 ) in a second component design, - computer-aided simulation of the production of the component ( 1 ) in the plant ( 200 ), wherein the component ( 1 ), based on a component platform ( 9 ) in the plant ( 200 ), is oriented in a second setup angle (W2), - computer-aided determination of a second, component-area-dependent surface roughness (RA2), - computer-aided determination of at least one second load-bearing cross-section (Q2) of the component ( 1 ) in the area of the determined second surface roughness (RA2). Apparatus according to claim 1 or 2, comprising the further steps of: evaluating the method steps according to claim 1 and / or claim 2 with regard to the relationships between the surface roughness (RA), the load-bearing cross-section (Q) and the orientation (W) of the component ( 1 ) in the plant ( 200 ), - determination of the orientation (W) of the component ( 1 ) in the plant ( 200 ), based on the evaluation of the previous process step, - production of the component ( 1 ) in the plant ( 200 ), based on the definition of the previous procedural step. Device according to one of the preceding claims, with the further step of: - using at least one material simulation for the computer-aided construction of the component ( 1 ) in at least one component design. Device according to one of the preceding claims, with the further step: - Using at least one influencing factor to take into account the material properties.

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